Machine for coating absorbent surfaces



June 1, 1943. F. E. DRUMMOND 2,320,513

MACHINE FOR COATING ABSORBENT SURFACES Original Filed May 16, 1940 3' H mm ms: HATER/AL (0A r50 wm/ mmumr or ADHESIVE 0 he. 4 mw/mz HMS/l HEX/31E BASE 11/7 TEX/14L NYE/V7017 F0150 E Owe/Y0 xl-A i p Patented June 1, 1943 UNITED STATES PATENT OFFICE.

MACHINE Fon COATING ABSORBENT SURFACES Folsom E. Drummond, Metuchcn, N. J., assignor to New Wrinkle, Inc., Wilmington, Del., a corporation of Delaware Original application May 16, 1940, Serial No.

335,591. Divided and this application Septem ber 24, 1941, Serial No. 412,092

12 Claims.

This invention relates to apparatus for applying coating compositions, and more particularly it deals with a machine for coating woven orduces the flexibility of the coated material to a great extent and where only a surface coating is required, the absorption of coating composition into the orous structure of the article being coated results wasteful and costly.

I have discovered that if the coating composition is applied on the porous material to be coated in the form of a dried or semidried film, such a film will adhere readily and firmly to the surface to be coated without there being absorbed into the body of the porous material any substantial quantityof the coating composition; thereby the original flexibility of the material to be coated is retained to a very great extent, there does not result any waste or excessive expense due to unnecessary absorption of coating-composition, and there is formed a laminated sheet material comprising an outer layer or film of coating composition deposited on the porous material without substantial pene tration thereof by the coating composition.

My invention provides an apparatus adapted for transferring a coating composition-such as a decorative or protective coating, in the form of a cured or set, or partially cured or set film or layer, onto the surface of a porous article and further adapted firmly to unite the film of coating material and the porous body.

The nature of the film united with the porous material will depend upon the specific nature of the porous material and the characteristics of the ultimate product that it is desired to manufacture. For instance, by the application of the coating machine of my invention, it is possible to coat a fabric or similar porous flexible sheet with a wrinkle finish without applyin the wrinkle finish on the fabric in the usual liquid form. By the application of the procedure permitted by the coating machine of my invention. I can do this without the costly and wasteful procedure of applying a wrinkling liquid coating composition, a substantial portion of which would be absorbed into the body of the fabric or similar porous material.

Obviously, the procedure permitted by the coating machine of my invention is not limited to the coating of fabric. For instance, a paper web or sheet may be coated with an ornamental wrinkle finish and would prove to be flexible and weather resistant.

As further typical applications of the coatin machine of my invention, I might mention the coating of awnings and similar articles of woven materials with ornamental flexible dried or semidried coating compositions. Using the coating machine of my invention, it is possible to .apply an ornamental flexible coating composition in a dried or semidried state and thereby obviate the necessity for coating the base material with a heavy filler base coating in order to prevent excessive absorption of the customary liquid coating compositions. Such heavy filler base coatings are generally required when using liquid coating compositions in order to insure the retention of a reasonably high degree of flexibility and a light weight product, but since there is no substantial penetration into the base material when using the coating machine of my invention, there is no need for such base coatings.

Another typical example of an application of the coating machine of my invention is in applying a coating film adapted to produce a wrinkle finish on a material possessing a heavy fibrous structure 'without obliterating the wrinkle pattern or texture of the coating composition.

Still further advantages and applications of the coating machine of my invention will be made evident by the following description taken in connection with the accompanying drawing in which:

Fig. 1 shows diagrammatically in elevation an apparatus for applying a coating film to a flexible base material according to a preferred embodiment of my invention;

Fig. 2 is a modified construction illustrating the use of a continuous belt conveyer for transferring the coating film onto a flexible base material;

Fig. 3 is an enlarged cross sectional detailed view of a flexible base material having a wrinkle finish coating film applied thereon; and

Fig. 4 is a view similar to Fig. 3, wherein an adhesive material is applied on the base material to be coated before the wrinkle finish film is placed thereon.

Referring to the drawing in detail, Fig. 1 illustrates a preferred embodiment of this invention wherein a drum I is mounted for rotation adjacent a drum II which are driven synchronously by means of a motor l2 and drive pulley means l3 which is connected to the respective pulleys l5 and IS on the drums l0 and II, respectively. The flexible base material, which may comprise fabric, felted or fibrous structures of a porous nature is' drawn around the drum II as shown at I8. The coating composition to be applied as a film to the flexible base material II is sprayed upon the surface of the drum ill by a suitable spray apparatus such as shown at l9 and the coating film is moved by the rotating drum under the radiant heat lamps 22 which are positioned adjacent the surface of the drum and focused thereon. These lamps are suitably controlled through the switch means 24 and resistance 25 so as to provide the proper amount of heat. In addition, a heating element 28 is positioned beneath the outer peripheral surface of the drum as shown at 28 and is likewise controlled through the switch 29 and resistance 30 so as to provide a proper degree of heat treatment. I Y

The drum III is rotated at a speed which will permit the coating'composition to be dried to a "soft flexible film as it reaches the opposite side of the drum. as at 32, whereupon it is peeled from the surface of the drum by the member 34 transferred to the surface of the drum H rotating adjacent thereto and which carries the flexible base material on which the film is to be applied.

A soft resilient roller means 35 is positioned to press against the drum II as shown in Fig. 1

so as to press the coating fihn firmly against the fabric or flexible base material l8. Suitable means such as a spring pressed member 31 is provided for varying the pressure which the roller 35 applies to the surface of the film as it passes over the roller II. The roller 35 is preferably made of porous rubber or the like material and sufficient pressure is exerted by this member to compress the coating film firmly against the base fabric without destroying the wrinkle or surface Where it is found that the film does not properly adhere by itself. the application of adhesive material in a thin film over the base of the fabric or fibrous material being coated may be made as illustrated in Fig. 4. In most instances, by

gauging the time of transfer of the film onto the base of the material, the coating film will have suflicient adhesive property to unite with the fabric or flexible base material. If desired, the base material carrying the coating film may be passed through a heated chamber to thoroughly dry the coating film thereon so as to produce a finished article. Air drying of the coating film on flexible base material may be provided for by suitably guiding the coated material over a number of guide rolls prior to storing or shipping the finished product.

In the modification shown in Fig. 2, an endless belt 40 is utilized for receiving the sprayed coating composition and conveying the film onto the flexible base material to be coated. In th lustration, the endless bclt means 40 is arranged to receive the spray material as shown at 42 and thereafter the endless belt passes through a drying compartment 45 which is provided with suitable heating means such as shown at 41. The dried coating film is stripped from the endless bclt by the member 5| as it passes around the guide roller 52 and is transferred onto the base material such as shown at 53. The flexible base material may be coated with a thin layer of adhesive and passed around the resilient roller 55 as shown in Fig. 2 and a corresponding rubber or resilient roller 511s positioned thereover to press the coating film firmly against the flexible base material as it passes over the roller 55. In this manner, the semidried or dried coating film is applied directly to the base material and securely attached thereto to form a laminated product having a high degree of flexibility. The

finished product provides a suitable method for ornamenting fabric and the like porous base material and produces a product which is durable and waterproof.

In order to provide for the ready removal of the dried coating film from the surface of the drum l0 and endless belt 40, the surfaces are preferably coated with soap, wax or the like substance which will withstand heat and not attack the film. In this manner, the film will not tenaciously adhere to the supporting base and can be readily detached by a doctor blade or similar means as shown at 34 and H whereby the film can be transferred onto the fabric or porous base material on which it is to be fixed. If desired, the surfaces upon which the coating is sprayed may be formed of metal and mercurized so as to provide a thin coating of mercury over the surface which permits the film to dry and be easily stripped from the temporary supporting surface. i

It will be understood that the apparatus and method as described may be modified so as to apply the coating film onto porous rigid articles, such as acoustic blocks or panels commonly used in the fabrication of walls and ceilings of buildlugs to eliminate sound disturbances.

This application is a division of my co-pending application Serial No. 335.591, filed May 16, 1940.

It will be understood that while I have described and illustrated certain specific embodiments of my invention and have set forth specific examples of its application. I do not intend that my invention be limited to or circumscribed by the specific details of construction and arrangement of parts herein described and illustrated. since my invention is adapted to modifications to suit different conditions and uses within the spirit and scope of the appended claims.

I claim:

1. An apparatus for applying wringle coating films to sheet material comprising a mercurized base surface for receiving a film of liquid wrinkle drying coating composition; means for applying heat for partially drying said film and developing a wrinkle texture on the exposed surface thereof means associated with said base for removing the partially dried wrinkle film and transferring it to the surface of said sheet material so that the under surface of the wrinkle film is in contact with the outer surface of said sheet material; and means for applying pressure firmly to unite the under surface of said film to the outer surface of said sheet material.

2. An apparatus for applying a wrinkle coating film to a flexible sheet material comprising a movable base means having a surface adapted to receive a film of liquid wrinkle drying coating composition, said surface being nonadherent to said wrinkle drying coating composition; means, for applying heat to said surface to dry to an initial set the wrinkle drying coating placed thereon; means coacting with said movable base for removing said wrinkle coating in the form of a partially dried wrinkle film; means comprising a movable member for supporting and bringing said material to be coated in contact with said wrinkle film so that the under surface of the wrinkle film is in contact with the outer sur face of said material; and means for firmly securing said wrinkle coating film onto said sheet material with the under side of said wrinkle film in contact with the outer side of said sheet material.

3. An apparatus for continuously applying a wrinkle finish coating film to a porous flexible sheet material comprising a rotatable surface means for receiving a wrinkle drying liquid coating in the form of a film; heat lamp means for applying radiant heat to said film to produce a tough flexible film having a wrinkled surface; means for removing said flexible wrinkled film from said surface; and means comprising a press roll having a porous yieldable surface for pressing said wrinkled coating film against the sur face of said sheet material firmly to secure the film thereto with the under side of said wrinkle film in contact with the outer side of said sheet material.

4. An apparatus for continuously applying a wrinkle finish coating film to a porous sheet material comprising an endless movable surface means which is adapted removably to support a liquid coating composition in the form of a film; means for drying said coating to produce a flexible wrinkle finish film; means cooperating with said movable surface for removing said dried wrinkle finish film; means for supporting and guiding said porous sheet material in position to receive said film as it is removed and transferring it onto the surface of said porous sheet material so that the under side of said film is in contact with the outer side of said sheet; and means comprising a porous rubber roll adapted firmly to secure the under side of said wrinkle finish film onto the outer side of said porous sheet material.

5. An apparatus for continuously applying wrinkle finish coating film to a fibrous material comprising a rotatable drum for receiving a spray coating of a, wrinkle drying composition; means for subjecting said coating to infrared radiant heat to produce a film having a wrinkle surface finish; means for peeling the wrinkle coating from said rotatable drum surface; rotat able means adapted to be synchronously driven with said drum surface for carrying said fibrous material in position to receive said peeled wrinkle coating film thereon so that the under side of said wrinkle film is in contact with the outer side of said base material; and yieldable roll means for compressing said fibrous base material and wrinkle finish film together with the under side of said film in contact with the outer side of said base material permanently to adhere said film and said base material without substan tially penetrating with said coating into said fibrous base.

6. An apparatus for finishing porous articles with wrinkle finish comprising an endless movable member having -a nonadherent surface adapted to receive a liquid coating composition; means for applying a wrinkle drying liquid coating composition onto the surface of said movable member; means for moving said surface while heating said coating film to produce a substantially dry wrinkle finish film; means engaging the surface of said movable member for removing said wrinkle film therefrom; means associated therewith for supporting and guiding said porous material to be coated adjacent said movable surface member; and means for adhesively uniting the under side of said wrinkle finish film and the outer surface of said fibrous base material to produce a laminated porous sheet material having a wrinkle finish.

'7. An apparatus for applying coating compositions onto articles in the form of a film layer comprising an endless movable member having a surface adapted to receive said coating composition in the form of a wet flowable mass, said endless surface being adapted to prevent the adherence thereto of the coating composition upon drying of the same; means for drying the coating while supported on said surface; means for removing said ,coating composition in the form of a film and transferring it to the article to be coated with the under side of said film in contact with the outer side of said article; means for supporting said article and simultaneously moving it parallel and in contact with said film; and means for firmly uniting the under side of said coating film and the outer surface of said article.

8. An apparatus for continuously applying wrinkle finish coatings to porous flexible articles having an adhesive surface comprising a movable base means for receiving a coating of a composition which will dry to a wrinkle finish, said movable base means having a surface which will inhibit the adherence of the coating composition thereto upon drying of the same and can be stripped readily therefrom; means for drying the coating composition to a wrinkle finish coating film; means for removing said wrinkle finish coating film from the initial supporting surface means and transferring it onto the surface of said porous flexible article with the under surface of said film in contact with the outer surface of said article; and means including pressure exerting rolls for permanently uniting the under side of said wrinkle finish film to the adhesive outer surface of the article to produce a wrinkle finish product.

9. In apparatus forfcombining web materials, in combination: rotatable drum means adapted to receive a spray of coating composition; heating means in association with said drum means adapted partially to set said coating composition; a second rotatable drum means adapted to cooperate with said first drum means, said second drum means being adapted to carry a web of flexible base material and further adapted to receive the partially set web of coating composition from said first drum means; scraper means adapted to remove said partially set web of coating composition from the surface of said first drum means; and idler drum means adapted to press the under side said partially set web of drying composition onto the outer surface of said web of flexible base material to form a unitary article comprising a web of flexible base material provided with an adhered film of'coating composition.

10. In apparatus for combining web materials,

in combination: endless surface means adapted to receive a spray of liquid coating composition; heating means in association with said endless surface means adapted partially to set said liquid coating composition in the form of a web; scraper means adapted to remove said partially set web of coating composition from the surface of said endless surface means; rotatable roll means adapted to carry a web of flexible base material and further adapted to receive the partially set web of drying composition removed from said endless surface means with the under surface of said partially set web in contact with the outer surface of said flexible base material; and rotatable pres roll means in association with said rotatable roll means adapted to press said web of partially set coating composition and said web of flexible base material into a unitary article.

11. An apparatus for providing articles or ma: terial having a. porous absorbent surface with an adherent coating film comprising a temporary base for receiving a liquid coating. means associated with said "base for accelerating the conversion of said liquid coating to a film which can be removed from said base. means for peeling said film from said temporary base and transferring it onto the surface of said porous material with the under surface of said film in con-' tact with the outer surface of said porous material, and means for applying pressure to said film and material to firmly unite the same.

12. An apparatus for applying a wrinkle finish coating to material having a porous-surface'which comprises a temporarybase adapted to removably support a liquid coating composition in the fort of a film. means for drying said coating to produce a flexible wrinkle finish film, means for supporting and guiding said porous surface material in positionto receive said wrinkle finish film as it is removed from said base with the under surface of said film in contact with the outer surface of said porous material, and means for applying pressure to said film to secure the same firmly to said material providing it with a durable wrinkle finish.

- FOLSOM E. DRUMMOND.

CERTIFICATE OF CORRECTION. Patent No. 2,520,515. June 1, 19 5.

. FOLSOM E. DRUMMOND.-

It is hereby certified that error appears in the printed specification of the above numbered patent requiring correction as follows: Page 2, sec-- 0nd column, line 60, claim 1, for "wringle" read --wrinkle--; and that the said Letters Patent should be read with this correction therein that the same inay conform to the record of the case in the Patent Office.

Signed and sealed this 29th day of June, A. D. 191g.

' Henry Van Arsdale, (Seal) 4 Acting Commissioner of Patents.- 

